Patent US4692199A successfully refreshed from Google Patents.
US4692199A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method and apparatus for bonding fabric to a foam pad
Assignee: Lear Corp
•
Filing: 1985-12-13
•
Granted: 1987-09-08
•
Expires: 2005-12-13
Abstract
Abstract A vacuum (15) as applied to a porous contoured mold (18) for drawing an impervious adhesive film (16) against a cloth fabric layer (14) to conform the cloth fabric layer (14) to the contours of the mold surface. A matching cellular foam cushion pad (12) is placed in mating engagement with the adhesive film (16) as it is held to the contour of the mold surface by the vacuum. The foam pad (12) is compressed against the mold (18) by a perforated platen (36) and held in place as the vacuum is discontinued. Steam is then supplied through the porous mold (12) to heat and diffuse the adhesive film (16) into the adjacent fabric layer (14) and cellular foam pad (12) for adhesively securing the two together. A partial vacuum is then applied for removing moisture by drawing air through the perforations (44) of the platen (36), the foam pad (12), fabric layer (14) and porous mold (18). This ambient air also cools and cures the diffused adhesive between the fabric (14) and the foam (12).
Inventors
- 👤 Eric F. Kozlowski
- 👤 Edmund R. Kruger
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 22:05
CPC Classifications
B; B29; B29C; B29C51/00; B29C51/26; B29C51/30; B29C51/36; B29C51/365; B29C44/00; B29C44/34; B29C44/56; B29C44/569; B29C51/16; B29C63/00; B29C63/02; B29C63/025; B29C51/08; B29C51/082; B29K; B29K2313/00; B29K2313/02; B29L; B29L2009/00; B29L2031/00; B29L2031/771
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
127 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), characterized by placing a cellular foam pad (12) in facing engagement with the adhesive film (16), and heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 2
Independent Claim
127 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), characterized by placing a cellular foam pad (12) in facing engagement with the adhesive film (16), and heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 3
Dependent Claim
30 words
A method as set forth in claim 1 further characterized by clamping the periphery of the adhesive film (16) against the underlying fabric layer (14) and over the mold (18).
Claim 4
Dependent Claim
28 words
A method as set forth in claim 1 further characterized by compressing the foam pad (12) against the adhesive film (16), fabric layer (14), and mold surface (18).
Claim 5
Dependent Claim
38 words
A method as set forth in claim 1 further characterized by placing the adhesive film over only a portion of the fabric layer to secure less than the entire fabric layer to less than the entire foam pad.
Claim 6
Independent Claim
158 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a cellular foam pad (12) in facing engagement with the adhesive film (16), compressing the foam pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the foam pad (12) is compressed against the mold surface (18), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 7
Independent Claim
158 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a cellular foam pad (12) in facing engagement with the adhesive film (16), compressing the foam pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the foam pad (12) is compressed against the mold surface (18), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 8
Dependent Claim
37 words
A method as set forth in claim 5 further characterized by supplying heated fluid over the mold surface (18) to melt and diffuse the adhesive film (16) into the foam pad (12) and fabric layer (14), respectively.
Claim 9
Dependent Claim
27 words
A method as set forth in claim 6 further characterized by applying a second vacuum over the mold surface after the adhesive film (16) has been heated.
Claim 10
Dependent Claim
21 words
A method as set forth in claim 7 further characterized by supplying steam as the heating fluid over the mold surface.
Claim 11
Dependent Claim
30 words
A method as set forth in claim 8 further characterized by applying the second vacuum to remove all moisture residue from the steam and for cooling to cure the adhesive.
Claim 12
Dependent Claim
25 words
A method as set forth in claim 9 further characterized as compressing the foam pad with a perforated platen movable relative to the mold surface.
Claim 13
Dependent Claim
29 words
A method as set forth in claim 10 further characterized by utilizing a porous mold and diffusing the vacuum and steam to the mold surface through the porous mold.
Claim 14
Independent Claim
154 words
A method of fabricating an assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a pad (12) in facing engagement with the adhesive film (16), compressing the pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the pad (12) is compressed against the mold surface (18), heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).
Claim 15
Independent Claim
154 words
A method of fabricating an assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), placing a pad (12) in facing engagement with the adhesive film (16), compressing the pad (12) against the adhesive film (16) and fabric layer (14) and mold surface (18), and discontinuing the vacuum after the pad (12) is compressed against the mold surface (18), heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).
Claim 16
Dependent Claim
35 words
A method as set forth in claim 12 further characterized by supplying heat to the mold surface (18) to melt and diffuse the adhesive film (16) into the pad (12) and fabric layer (14), respectively.
Claim 17
Dependent Claim
28 words
A method as set forth in claim 13 further characterized by applying a second vacuum over the mold surface (18) after the adhesive film (16) has been heated.
Claim 18
Independent Claim
161 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and the urge the fabric layer (14) against the mold surface (18), utilizing a mold (18) having a contoured mold surface, and moving a preformed foam pad (12) having the opposite contoured surface over the adhesive film contoured to the mold surface and into mating and non-slipping engagement therewith, placing a cellular foam pad (12) in facing engagement with the adhesive film (16), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 19
Independent Claim
161 words
A method of fabricating a cushion assembly (50, 50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and the urge the fabric layer (14) against the mold surface (18), utilizing a mold (18) having a contoured mold surface, and moving a preformed foam pad (12) having the opposite contoured surface over the adhesive film contoured to the mold surface and into mating and non-slipping engagement therewith, placing a cellular foam pad (12) in facing engagement with the adhesive film (16), heating and diffusing the adhesive layer (16) into the foam pad (12) and fabric layer (14) respectively, and curing the diffused adhesive to secure the fabric layer (14) to the foam pad (12).
Claim 20
Independent Claim
124 words
A method of fabricating an assembly (50,50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), characterized by placing a pad (12) in facing engagement with the adhesive film (16), and heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).
Claim 21
Independent Claim
124 words
A method of fabricating an assembly (50,50') comprising the steps of; placing a fabric layer (14) over a mold surface of a mold (18), placing an air impervious adhesive film (16) over the fabric layer (14), applying a vacuum pressure over the mold surface (18) and through the fabric layer (14) to draw the adhesive film (16) down against the fabric layer (14) and to urge the fabric layer (14) against the mold surface (18), characterized by placing a pad (12) in facing engagement with the adhesive film (16), and heating the adhesive film (16) to adhere the adhesive film (16) to the pad (12) and fabric layer (14), respectively, and curing the adhesive to secure the fabric layer (14) to the pad (12).
Claim 22
Dependent Claim
30 words
A method as set forth in claim 16 further characterized by clamping the periphery of the adhesive film (16) against the underlying fabric layer (14) and over the mold (18).
Claim 23
Dependent Claim
27 words
A method as set forth in claim 16 further characterized by compressing the pad (12) against the adhesive film (16), fabric layer (14), and mold surface (18).
References Cited (Backward Citations)
US3320108A
Cited
US3654019A
Cited
US4025372A
Cited
US4114213A
Cited
JPS5366978A
Cited
JPS5514526A
Cited
US4264386A
Cited
US4559094A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-09-07 | 1991-03-09 | 1991-09-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-09-07 | 1995-03-09 | 1995-09-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-09-07 | 1999-03-09 | 1999-09-08 | $7700.00 | Window Closed / Lapsed |